Building structure and modular construction method

ABSTRACT

A building structure comprising one or more modular panels ( 5 ); a wall locating member ( 12 ) positioned between a base ( 2 ) and the one or more modular panels ( 5 ); a top member ( 19 ) placed on top of the modular panels ( 5 ); and a plurality of tie rods ( 14 ). The modular panels ( 5 ) when adjoining to form a wall create longitudinal cavities ( 16 ) within the wall. The plurality of tie rods ( 14 ) extend through said longitudinal cavities ( 16 ) and secure said top member ( 19 ), walls ( 3 ) and wall locating member ( 12 ) to the base ( 2 ).

[0001] THIS INVENTION relates to building structures employing modularstructural panels and also to an improved construction method forassembling such modular panels to form such a building.

BACKGROUND TO THE INVENTION

[0002] The prior art is replete with modular building structures andassociated construction methods, many of which suffer from a variety ofproblems. Amongst such problems are included the complexity ofassembling elaborate framing systems to which modular panels areattached, the inconvenience attendant the use of plural individualfasteners to fix structural panels to one another, and the poorstructural strength of some modular structures.

[0003] An example of a prior art modular construction arrangement whichemploys a plurality of fasteners is U.S. Pat. No. 4,858,398 in the nameof Ricchini. Ricchini discloses a structure using proportionally sizedpanels secured together by turn-lock fasteners inserted through alignedopenings in adjacent sides of panels.

[0004] A further exemplary prior art construction arrangement is thatdisclosed in French Patent Document Number 2389724 in the name ofBatimpro S A. This document discloses a modular building using panelshaving adjacent vertical sides of complementary shapes. The panels arejoined together by screws and are reinforced with metal plates at thelocation of the joints.

[0005] Reference may also be made to the method and apparatus formanufacturing foamed plastics laminated panels for modular buildingapplications as disclosed in the applicant's Australian Patent No.620338. Panels manufactured in the manner described therein are anexample of those suitable for use with the present invention. Oneparticular advantage of the applicant's previously disclosed method isthat the panels may be conveniently fabricated at the building site.

OBJECT OF THE INVENTION

[0006] It is an object of the present invention to provide a buildingstructure employing modular panels which overcomes or ameliorates atleast some of the problems associated with the prior art.

[0007] It is a further object of the invention to provide a constructionmethod employing modular panels which is simple but maintains thestructural integrity of a completed building structure, thus providing amore convenient alternative to those presently available.

[0008] A yet further object of the invention is to provide a laminatedmodular panel adapted for use with the building structure and/orconstruction method which may also be expediently fabricated.

[0009] Further objects will be evident from the following description.

DISCLOSURE OF THE INVENTION

[0010] In one form, although it need not be the only or indeed thebroadest form, the invention resides in a building structure comprising:

[0011] one or more modular panels;

[0012] a wall locating member positioned between a base and the one ormore modular panels;

[0013] a top member placed on top of the modular panels; and

[0014] a plurality of tie rods;

[0015] wherein, said modular panels when adjoining to form a wall createlongitudinal cavities within the wall; and

[0016] wherein, the plurality of tie rods extend through saidlongitudinal cavities and secure said top member, walls and walllocating member to the base.

[0017] It is preferable that the modular panels comprise recesses onopposing longitudinal sides (herein after referred to as thelongitudinal recess) of the adjoining panels, thereby defining, in use,the longitudinal cavity between the adjoining modular panels.

[0018] The top member provides a capping and/or compression feature tothe walls of the building structure. The top member may comprise acapping member and/or a compression member.

[0019] Suitably the wall locating member and the top member, when it isa capping member, are both C section channelling. For the wall locatingmember the C channelling is placed so as to form a U and for the cappingmember the C channelling is placed so as to form an inverted U over thetop of the modular panels.

[0020] In one form an upright channel member may be fixed to one face ofa modular panel for locating modular panels to form a corner or internalwall.

[0021] In preference the tie rods possess high tensile strength.

[0022] The tie rods may be releasably engageable with mounts provided atpredetermined positions along the base.

[0023] In preference the modular panels are of a laminated construction.

[0024] The modular panels are suitably formed from foamed plasticslaminated panels having at least one outer skin member.

[0025] The modular panels may comprise an additional longitudinalaperture for accommodating a tie rod, located some distance in from thelongitudinal recess, for the formation of a corner or join.

[0026] It is preferable that the base includes a floor structure, whichmay optionally be of modular construction, also employing laminatedpanels. Suitably the laminated panels for the floor comprise a ribbedouter steel skin, a foamed plastic core and a ribbed inner skin. Thelaminated floor panels made of a ribbed construction are preferablylined with composite flooring, waterproof ply or timber floor.

[0027] The building structure may also include a roof structuresupported by the walls, which roof may also be of modular construction,employing further laminated panels. The laminated panels for the roofmay comprise a ribbed outer steel skin, a foamed plastic core and aribbed inner skin. The ribbed roof panel construction is preferablylined with fiber-cement board, plasterboard, random grooved ply ortimber.

[0028] In a further form the invention resides in a method ofconstruction including the steps of:

[0029] placing one or more wall locating members on a base;

[0030] erecting one or more modular panels on the wall locating membersto form one or more walls;

[0031] engaging adjacent modular panels to define longitudinal cavitiesbetween longitudinal recesses formed on upright sides of said modularpanels;

[0032] placing a top member on the upper edge of the modular panels;

[0033] inserting tie rods through the top member and longitudinalcavities;

[0034] connecting the tie rods to the base to secure the top member,modular panels and wall locating member thereto, to form walls.

[0035] The step of placing the top member on the upper edge of themodular panels may comprise the steps of;

[0036] placing a capping member on the upper edge of the modular panel;and

[0037] is placing a compression member on top of the capping member.

[0038] In a yet further form, the invention resides in a modular panelfor use in the abovementioned building structure or method ofconstruction, wherein said modular panel comprises:

[0039] a core of foamed plastics material;

[0040] at least one outer skin member bonded to said core;

[0041] two longitudinal recesses on opposing longitudinal sides of themodular panel which define, in use, a longitudinal cavity extendingalong the junction between adjoining modular panels.

[0042] The modular panels may have an additional longitudinal cavity,sized so as to receive a tie rod, wherein the longitudinal cavity islocated toward an end of the modular panel but inwardly from thelongitudinal recess.

BRIEF DETAILS OF THE DRAWINGS

[0043] To assist in understanding the invention, preferred embodimentswill now be described with reference to the following figures in which:

[0044]FIG. 1A is a front elevation of an exemplary building structure;

[0045]FIG. 1B is an end elevation of the building structure;

[0046]FIG. 1C is a schematic plan view of the building structure showingthe arrangement of modular panels comprising the walls;

[0047]FIG. 2A is an enlarged partial sectional view of the structure'sbase showing the junction of the floor structure with an outer wall;

[0048]FIG. 2B is an enlarged sectional view of the portion of FIG. 2A inthe circle.

[0049]FIG. 3A is an exploded isometric view illustrating the erection ofmodular panels to form a wall, wherein the top member is a cappingmember;

[0050]FIG. 3B is an exploded isometric view illustrating the erection ofmodular panels to form a wall, wherein the top member comprises acapping member and a compression member;

[0051]FIG. 3C is an enlarged detail view of an optional arrangement forlocating the bottom side of the modular panels;

[0052]FIG. 4 are enlarged sectional plan views of the aligned laminatedpanels showing the configuration of the positive positioning profiles onthe laminated panels;

[0053]FIG. 5 is an enlarged partial sectional view of the roof areashowing an arrangement of the fascia;

[0054]FIG. 6A is an end elevation of a modular roof panel;

[0055]FIG. 6B is an enlarged detailed view of the showing thepositioning profiles on the roof panels;

[0056]FIG. 7 is an exploded isometric view showing the arrangement ofcorner junctions and tee-junctions of the walls; and

DETAILED DESCRIPTION OF THE DRAWINGS

[0057] In general, FIG. 1 shows a building structure 1 in the nature ofa small dwelling which may be constructed in accordance with theinvention. The structure includes a base 2, a number of walls 3 and aroof 4. The walls, whether external or entirely internal, are composedof modular panels 5. The modular panels are fabricated to a typicalmodule size of 900 mm wide by 3.0 m high. In some situations largerpanels may be used, particularly to accommodate the pitch of a roof. Themodular panels are secured to the base by tie rods (described later)which are disposed along the walls at 900 mm centres 6. Additional tierods are disposed at the sides of openings in the walls 7 and at thecomers 8 of the building structure.

[0058] The wall panels may be erected on a concrete or timber floor or,as illustrated in FIG. 2A, on a floor comprised of further laminatedpanels attached to screw-in foundations. In the later arrangement, thebase 2 comprises floor panels 9 supported by an inverted T member 10mounted on screw-in foundations 11.

[0059]FIG. 2A also shows floor panels 9 are mounted to the other half ofthe inverted T member 10 (the inner most horizontal face). The floorpanels 9 are generally attached via screws 17A.

[0060]FIG. 2B shows a wall locating member 12, in the form of a Csection channel, mounted on the outermost half of the inverted T member10. The modular wall panels 5 are located in the wall locating member12. Threaded studs 13, for securing respective tie rods 14, are fastenedto the horizontal face of the outer most half of the inverted T member10 by welding, screwing or the like and protrude through the walllocating member 12 and into longitudinal cavity 16 for engagement with anut 15 fastened to the end of each tie rod 14. The tie rods 14 extendthrough respective longitudinal cavities 16 provided in the upright wallpanels 5. The studs project through the wall locating member 12, via anaperture 17.

[0061] The overall arrangement of wall panels may be better understoodby reference to the exploded view of the base 2 and partially completedwall 3 shown in FIG. 3A and 3B. In accordance with the invention,individual wall panels 5 are erected and aligned such that thelongitudinal cavities 16, which are defined when the panels adjoin oneanother, correspond to the studs 13 and cooperating apertures 18 in thewall locating member 12.

[0062] Each tie rod 14 is inserted into a respective longitudinal cavity16 and engaged with a stud 13 disposed at the lower extremity of thecavity 16. The top member 19 is then placed so as to form an inverted Uover the top side of the wall panels. Apertures 22 in the top member 19,are sized to accommodate the shaft of the tie rods 14 and are spaced soas to correspond to the studs 13. Thus the upper ends of the rodsprotrude through said apertures 22 in the top member 19 when they arepositioned on the modular wall panels. The upper end of the tie rods 14may be screw threaded and engageable with a nut 23 to facilitate thetensioning thereof. The nuts 23 are engaged with the rods and tightenedagainst the top member 19.

[0063]FIG. 3B illustrates the partial completion of a wall, similar tothat of FIG. 3A, but wherein the top member 19 comprises a cappingmember 20 and a compression member 21. The compression member 21 isplaced on top of the capping member 20. Apertures 22 and 22A in both thecapping member 20 and compression members 21 respectively, are sized toaccommodate the shaft of the tie rods 14 and are spaced so as tocorrespond to the studs 13. Thus the upper ends of the rods protrudethrough said apertures 22 and 22A in the capping member 20 and thecompression member 21 when they are positioned on the modular wallpanels. The upper end of the tie rods may be screw threaded andengageable with a nut 23 to facilitate the tensioning thereof. The nuts23 are engaged with the rods and tightened against the compressionmember 21.

[0064]FIG. 3C illustrates in detail the locating the modular panels 5placed in the wall locating member 12, so that the cavity 16 is alignedwith the cooperating aperture 18 in the wall locating member 12, toallow the tie rods 14 to engage with the base 2.

[0065] For ease of description the subsequent embodiments will describethe top member comprising a capping member and a compression member. Itwill be appreciated by the person skilled in the are that the exactnature of the top plate may vary depending on the building type underconstruction and the exact location of the top plate(s) within thebuilding construction.

[0066] In an alternative embodiment (not illustrated), the rods areexternally screw threaded at both lower and upper ends thereof. Thelower end engages with an internally screw threaded stud adapted, forexample, for friction fitting in holes drilled into a concrete floor.Further alternatives for securing the tie rods will be apparent to theskilled addressee. The use of tie rods, preferably of high tensilestrength, in accordance with the invention overcomes problems withfasteners, such as screws or the like, being pulled out of the modularpanels in high wind load conditions. The invention also overcomes anyrequirement for local reinforcement of the modular panels which mightotherwise add to the cost and complexity of panel fabrication.

[0067]FIG. 4 shows in plan a schematic of one form of the longitudinalrecesses formed on the upright sides of the wall panels. The lightweightpanels 5 comprise a core 25 of foamed plastics, such as polyurethane andouter skins, such as fiber-cement sheeting 26. The core is typically 66mm thick whilst the skins are between 4.5 and 7.5 mm. The modular panelsmay be made of a thinner inner skin and a thicker outer skin. Thethinner inner skin is typically 4.5 mm while the thicker outer skin istypically 7.5 mm. The thicker outer skins may suitably be stucco fiber,whilst the inner skins may suitably be a plasterboard or timber finish.The longitudinal cavity 16 is formed from the two recesses 27 and 27A onthe facing edges of the panels, as shown on the panels which are alignedwith one another in FIG. 4A.

[0068] When the panels are adjoined, see FIG. 4B, a longitudinal cavity16 is formed between the recesses 27 and 27A. The cavity is sized foraccommodating a tie rod 14. Further subsidiary cavities 29 may beprovided immediately under the panel skins for accommodating buildingservices such as electrical wiring (not shown).

[0069] A first embodiment of a roof for the building structure isillustrated in FIG. 5. In this embodiment the roof 4 has a minimumpitch, typically of from 3 to 10 degrees, and is supported directly bythe external walls 30 and by the internal walls 31. The roof may also becomprised of modular panels as discussed in more detail below inrelation to FIG. 6A.

[0070] The roof panels 33 are secured at one end to the external walls30 by screws 34 which pass through the roof panels 33, compressionmember 21 and capping member 20 before engaging with the modular wallpanel 5. At the other end, near the ridge, the screws 34 securing theroof panels engage with supporting internal walls 31 in the same manneras with the external walls 30. The peak portion of the roof panels iscovered by ridge capping 36 which extends over the roof panel securingscrews 34, which capping is secured to the roof by further screws 36A.

[0071] As shown in FIG. 6A, the modular roof panels 33 in thisembodiment include a 25 mm ribbed steel outer skin 37 and an injectedpolyurethane foam core 38 which has a 25 mm ribbed steel inner skin 39,the panel is typically 100 mm thick. The underside of the roof panel islined (39A). The roof lining (39A) may be 4.5 mm fiber-cement board, 10mm plasterboard, random grooved ply or a timber ceiling screwed directlyonto the ribbed steel inner skin. Suitably the roofing panel ishi-tensile spandeck steel sheeting. Wooden support blocks 40 areembedded in the core at spaced locations along one side of the roofpanel to provide mounting points for the fascia panel 41, shown in FIG.5.

[0072] The floor panels described in FIG. 2 may also be made of asimilar panel construction as the roof panels described above and inreference with FIG. 6. More preferably the floor panels are also formedfrom hi-tensile spandeck steel sheeting. When formed by the hi-tensilespandeck steel sheeting, the floor panels are lined with eithercomposite flooring, waterproof ply or a timber floor applied directlyonto the sheeting by screws or glueing.

[0073] The use of hi-tensile spandeck sheeting for roof and floor panelshas the advantage of having high strength, light weight, and being ableto span up to 7 metres, thereby providing easy of construction whilstreinforcing the building strength.

[0074] The enlarged detail view of the roof panel joint in FIG. 6B showsthe arrangement of a projection 42 and cooperating recess 43 formed inthe sides of the foam core 38 of a roof panel 33. The enlargement showsa ridge 37A of the outer roof skin extending laterally past the coresuch that, when two cooperating roof panels are engaged, the extendedridge 37A clips over the ridge nearest the side of an abutting roofpanel. The core may also be undercut in the vicinity of the projectionso as to produce a longitudinal cavity 44 when the roof panels areclipped together. This cavity may accommodate building services in thesame manner as the subsidiary cavities provided in the wall panels.

[0075] Returning to FIG. 5, the outer roof skin is turned-up 45 at thepeak end edge thereof to minimise any leakage. The roof skin alsoextends past the foam core 38 and coplanar embedded wooden blocks 40, soas to overhang the guttering 46 at the fascia end 47. The wood or metalfascia panel 41 is suspended under the valleys of the overhung roof skinby screws 48 and attached to the embedded support blocks 40 by a furtherseries of screws 49. The screws which are sunk into the fascia supportblocks also pass through gutter brackets 50 which brackets in turnsupport the guttering 46.

[0076] The drawings in FIG. 7 show the arrangement of the corners andtee-junctions of walls, in particular, the alternative arrangements ofthe capping and compression members at these junctions. A completedouter wall 30 is shown in place upon the base 2, with a capping member20 and compression member 21 on the top side thereof engaged by tie rodnuts 22. The wall junctions commonly include positioning profile members51 which are attached upright to the completed wall 30 at selectedpositions by screws 52. Wall locating members 12 are fixed upon thefloor surface or base 2 to locate the modular panels making up thewalls.

[0077] An outer wall panel 53 is shown ready to be positioned at thecorner of the structure, whereby the recess 53A in the upright side ofthe outer wall panel cooperates with the nose 51A of the positioningprofile member. At a corner the capping member 20 to be placed on one ofthe walls will have about 75 mm removed from the inner side of the Cchannelling. The remaining horizontal and outer side faces of the Cchannelling capping member then run to the outer edge of the corner.

[0078] The capping member 20 on the joining wall simply adjoins oroverlaps the capping member with a side partially removed. Thecompression members 21 at the comer joint are machined to half thicknessfor the length of the comer joint, thus forming half thickness tongues.These half thickness tongues are arranged so that the compressionmembers interlace or overlap, resulting in an even thickness of thecompression members at the comer. One of the modular panels forming thecomer join has an additional longitudinal cavity, capable of receiving atie rod 14. This additional longitudinal cavity is located so as to beat the centre of the corner join. Apertures 55 and 55A are provided onthe capping members 20 and compression members 21 to facilitate fixingthe members together and corresponding to the additional longitudinalcavity of the modular panel, thereby contributing to the structuralintegrity of the building.

[0079]FIG. 7 also shows the tee-junction arrangement of an internal wallwhere a tie rod in an intersecting wall is not in immediate proximity,but is provided at the intersecting end of the internal wall. Theinternal wall panel 57 (shown in fragmentary form) engages with therespective positioning profile member 51, in a similar fashion as twoengaging panels (recall FIG. 4B), thereby defining a longitudinalcavity. The capping member 58 and compression member 59 includeapertures 60 & 60A at their extremities. The capping member 58 andcompression member 59 are then disposed on the top side of the internalwall comprised of like panels 57. The tie rod 14, provided for the endof the internal wall, may then be inserted through the apertures 60 and60A and down into the cavity for securing the internal wall 57.

[0080] Throughout the specification the aim has been to describe thepreferred embodiments of the invention without limiting the invention toany one embodiment or a specific collection of features.

1. A building structure comprising: one or more modular panels; a walllocating member positioned between a base and the one or more modularpanels; a top member placed on top of the modular panels; and aplurality of tie rods; wherein, said modular panels when adjoining toform a wall create longitudinal cavities within the wall; and wherein,the plurality of tie rods extend through said longitudinal cavities andsecure said top member, walls and wall locating member to the base. 2.The building structure of claim 1, wherein the top member is a cappingmember.
 3. The building structure of claim 1, wherein the top member isa compression member.
 4. The building structure of claim 1, wherein thetop member comprises a capping member and a compression member.
 5. Thebuilding structure of claim 1, wherein the modular panels compriserecesses on opposing longitudinal sides of the adjoining panels, therebydefining, in use, the longitudinal cavity between the adjoining modularpanels.
 6. The building structure of claim 1, wherein the wall locatingmember and the top member are both C section channelling.
 7. Thebuilding structure of claim 1, wherein an upright channel member isfixed to one face of a modular panel for locating modular panels to forma comer or internal wall.
 8. The building structure of claim 1, whereinthe tie rods are releasably engageable with mounts provided atpredetermined positions along the base.
 9. The building structure ofclaim 1, wherein the modular panels are of a laminated construction. 10.The building structure of claim 9, wherein the modular panels are formedfrom foamed plastics laminated panels having at least one outer skinmember.
 11. The building structure of claim 1, wherein the modularpanels comprise an additional longitudinal aperture, located inwardlyfrom the longitudinal recess, for accommodating a tie rod in theformation of a comer or join.
 12. The building structure of claim 1,wherein the base includes a floor structure, which may optionally be ofmodular construction, also employing laminated panels.
 13. The buildingstructure of claim 12, wherein the laminated panels for the floorcomprise a ribbed outer steel skin, a foamed plastic core and a ribbedinner skin, and preferably the floor is lined with composite flooring,waterproof ply or timber floor.
 14. The building structure of claim 1,further comprising a roof structure supported by the walls.
 15. Thebuilding structure of claim 14, wherein the roof structure is also ofmodular construction, and employing further laminated panels.
 16. Thebuilding structure of claim 15, wherein the laminated panels for theroof comprise a ribbed outer steel skin, a foamed plastic core and aribbed inner skin and are preferably lined with fibre-cement board,plasterboard, random grooved ply or timber.
 17. A method of constructionincluding the steps of: placing one or more wall locating members on abase; erecting one or more modular panels on the wall locating membersto form one or more walls; engaging adjacent modular panels to definelongitudinal cavities between longitudinal recesses formed on uprightsides of said modular panels; placing a top member on the upper edge ofthe modular panels; inserting tie rods through the top member andlongitudinal cavities; connecting the tie rods to the base to secure thetop member, modular panels and wall locating member thereto, to formwalls.
 18. The method of construction of claim 17, wherein the step ofplacing the top member on the upper edge of the modular panels comprisesthe steps of; placing a capping member on the upper edge of the modularpanel; and placing a compression member on top of the capping member.19. A modular panel for use in the building structure of claim 1 ormethod of construction of claim 17, wherein said modular panelcomprises: a core of foamed plastics material; at least one outer skinmember bonded to said core; two longitudinal recesses on opposinglongitudinal sides of the modular panel which define, in use, alongitudinal cavity extending along the junction between adjoiningmodular panels.
 20. The modular panels of claim 19, wherein the modularpanel further comprises an additional longitudinal cavity, sized so asto receive a tie rod; wherein the longitudinal cavity is located towardan end of the modular panel but in from the longitudinal recess.